DEFEAT DESTRUCTIVE VARNISH TO OPTIMIZE TURBINE PERFORMANCE

The VARTECH™ Solution

Turbines are at the heart of your operation. If they’re attacked by varnish, your production could halt.Industrial operators have long been aware of the

tremendous damage that varnish can do to their

operations. Many of them know that varnish can

lead to a range of equipment problems, from poor

performance to catastrophic failures. They typically

consider varnish, and the difficulties that come

with it, as inevitable to doing business – something

that’s beyond their control.

You do not have to accept this.

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RESERVOIR HATCH COVERTHRUST BEARING TILT PAD

RESERVOIR FLOOR HEAT EXCHANGER COOLING PLATE

The CulpritVarnish is a coating that adheres to internal surfaces, wears out

equipment components, restricts performance and can ultimately

cause failures. It is composed primarily of organic residue mixed

with metals, inorganic salts and other contaminants. Varnish can

take different forms, from a sticky coating to a hard lacquer, and

ranges in color from gray to brown to amber. Varnish is very

destructive and hard to remove.

The CausesVarnish is formed when high operating temperatures deplete

protective additives, causing the lubricant to oxidize and break

down. Water, chemicals, particles, gasses and other contaminants

also act to degrade the oil. Elements of this degradation, known as

varnish precursors, precipitate out of the oil and attach themselves

to internal surfaces. The tacky nature of these deposits attracts

more and more precursors, and varnish builds up layer by layer.

To defeat varnish, you first must understand it

The Cycle of FailureAs varnish worsens, a vicious cycle

is often set in motion. The coating

insulates metal surfaces which

prevents efficient oil cooling which

raises the temperature. This causes

more more degradation and less

effective lubrication. More precursors

are created, more varnish layers are

formed, and the problem spirals

toward equipment failure.

The ConsequencesEven the smallest amount of varnish can result in poor system

performance and equipment failures. Valves stick, bearings overheat,

components wear out, oil inlets and filters clog, and the internal

mechanics of your turbine begin to malfunction. These issues tend

to worsen over time as more varnish builds up, leading to shortened

oil life, poor equipment performance and premature shutdowns.

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The experts at Caltex Lubricants have

developed a two-step, clean-and-control

solution to help you protect equipment

from varnish and ensure peak productivity

in your operation:

The VARTECH™ Solution

It’s time to fight back Varnish attacks turbines from the inside, destroys performance and threatens operations

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Eradicate varnish that has infiltrated your turbine systemVARTECH™ Industrial System Cleaner (ISC) utilizes proprietary

technology to do the most thorough and efficient cleaning

job without creating operational constraints.

Its triple-action technology:

VARTECH™ ISC helps prepare your equipment for fresh oil. A Caltex

lubrication specialist can work with you to recommend an optimized

cleaning cycle time to effectively remove sludge and stubborn, baked-on

varnish from your system. However, if unexpected delays are encountered,

you can feel confident knowing that the cleaner can temporarily remain

in your system without damaging internal components.

CUTS

It cuts through the hard varnish layers and

removes them as micro-sized particles.

CAPTURES

It captures and stabilizes these varnish particles

in a protective barrier so they can be removed

from your system without redepositing in other

parts of the equipment.

COMPATIBLE

It is compatible with the in-service oil for optimum

operational flexibility while maintaining performance

during the cleaning cycle that prepares the system

for change out to fresh oil.

VARTECH™ Industrial System Cleaner

STEP 1: CLEAN

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Run system normally

Monitor oil quality and schedule oil

change as needed

Replace filters and add fresh oil

Drain and rinseDetermine

whether to clean this cycle

Determine cleaner % and residence time

NO CLEANING

CLEANING PROCESS

Run system normally for

cleaning period

Add VARTECH ISC to running system

Replace system filters

CLEANING PROCESS

Maximize operational efficiencyClean without compromise

VARTECH™ ISC COMPETITIVE CLEANERS

• Turbines remain online and productive

• Varnish micro-particles are gradually removed to avoid overwhelming filters

• Compatible with internal equipment components, including seals

• Demonstrated compatibility with most turbine and compressor oils

• Minimally impacts performance of new oil

• Compatibility with the in-service oil can allow longer residence time (if needed) for better removal of stubborn, baked-on varnish

• Can temporarily remain in the system, causing no operational constraints

• Efficient cleaning process saves time and money

• Shutdown sometimes required

• Large pieces of varnish can break loose and settle in other areas of the system

• Harsh chemicals can damage seals and cause leaks

• Has the potential to lower lubricant flash point causing higher fire and explosion risk

• May accelerate oil degradation, shorten oil life and cause system corrosion

• Short cleaning cycle doesn’t effectively clean

• Repeated filter plugging and shorter filter life

• Shorter equipment life and higher maintenance costs

AFTER CLEANING WITH VARTECH™ ISC

BEFORE CLEANING

AFTER CLEANING WITH COMPETITIVE CLEANERS

The VARTECH™ Industrial System Cleaner (ISC) cleaning process

is simple, streamlined and economic. Conventional system cleaners

are more complex and require additional steps, external filtration

and multiple rinses and compatibility tests.

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VARTECH™ INDUSTRIAL SYSTEM CLEANER

The Equipment

Two Solar Titan 130 gas turbines are configured in

generator sets that deliver 15,000 kW of electricity

to the platform. Power loss would halt production.

The Problem

Varnish in the oil coolers was causing the unit to

run hot, triggering high-temperature alarms. The

operator tried a conventional cleaner, which created

operational challenges during the cleaning process

and only temporarily lowered the temperatures.

The operation had to resort to costly mitigation

measures, sending the coolers onshore every

4 months to clean the varnish, costing the

operation $80,000+ per year.*

The Solution

VARTECH™ Industrial System Cleaner (ISC) was

added to the in-service oil, and temperatures quickly

dropped below alarm levels. There were no filter

clogging problems, and the operator no longer

had to live with the varnish problem.

Cleaning with VARTECH™ Industrial System Cleaner helped save $80K+ in annual maintenance costs.*

AFTER CLEANING: Varnish film cleaned using VARTECH™ ISC

STEEL PLATES FROM OIL COOLER

BEFORE CLEANING: Varnish film

SPAR FLOATING PLATFORM, TAHITI FIELD, GULF OF MEXICO

Turbine operation temperatures kept below alarm levels

*Actual savings can vary.10

CASE STUDY | OIL & GAS OFFSHORE PRODUCTION

The Equipment

Solar Taurus 60 gas turbine is used in a steam/

electricity co-generation configuration. The steam

facilitates oil recovery and the electricity is sold

to a power utility.

The Problem

Varnish in the turbine oil coolers was causing the

unit to run too hot to operate at full design capacity,

and the operation was losing $350,000 annually

from lost electricity sales.

The Solution

VARTECH™ Industrial System Cleaner (ISC) was

added to the in-service oil, cleaning the varnish

from the oil coolers. Operating temperatures

quickly dropped and the turbine returned to full

design capacity, recapturing the lost $350,000.*

Cleaning with VARTECH™ Industrial System Cleaner helped achieve $350K in annual revenue gain.*

SJV WAS ABLE TO OPERATE THE GAS TURBINE AT FULL CAPACITY WITH NO TEMPERATURE ALARMS

BEFORE VARTECH™ ISC

AFTER VARTECH ISC IMPACT

Header temp.

159 154 -5ºF / -20ºC

Bearing temp.

206 194 -12ºF / -24ºC

Unit output (MW)

3.3 5.5 +2.2

Turbine operation maintained at full design capacity

SAN JOAQUIN VALLEY BUSINESS UNIT, CALIFORNIA

* Results may vary depending on equipment type, operating conditions and utility costs.

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CASE STUDY | POWER GENERATION

:

Prevent the formation of new varnishAfter existing varnish has been cleaned from your system, it

is important to refill your equipment with a lubricant that helps

prevent the formation of new varnish. Caltex has developed

advanced lubrication chemistry which inhibits the precursors that

can form in your oil stream, deposit on internal surfaces and eventually

become varnish.

Caltex lubrication experts are formulating a range of lubricants

with VARTECH Technology to protect operations across a number

of industries. Our first products will be GST® turbine oils formulated

with VARTECH Technology.

They are developed to control the formation of varnish and help:

• Improve oxidation stability

• Reduce oil degradation

• Extend oil life.

The VARTECH Solution for varnish control leads to full-on protection for your equipment, so you can achieve peak performance, reliability and productivity.

Lubricants Formulated with VARTECH™ Technology

STEP 2: CONTROL

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Contact the experts at Caltex industrial lubricants to help you tackle precisely the right lubrication program to protect equipment performance.

Detect varnish, then defeat itThe best way to prevent varnish from attacking your equipment

is to detect it early and take decisive action. Fluid monitoring and

oil analysis are excellent methods for tracking the health of your

lubricating system, but while they can detect varnish precursors

in your oil stream, they can’t detect varnish that has already formed.

Look for changes in oil color, spiking temperatures or visible varnish

deposits during routine maintenance.

You can also run a number of tests to monitor the health of your

lubricating system. Ruler-voltammetry testing can measure oxidation

trends in your oil. Membrane patch colorimetry (MPC), RPVOT and

particle count testing can help you measure oil degradation and

determine lubricant condemning limits.

Run Better LongerCaltex Lubricants has developed advanced expertise, premium

lubricants and targeted programs for a broad array of industries,

to help our customers’ equipment and operations Run Better Longer.

Find out more at chevronlubricants.com

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